Method for producing 6-chlorodibenzo[D,F] [1,3,2] dioxaphosphepin

ABSTRACT

The invention relates to a method for producing 6-chlorodibenzo[d,f][1,3,2]-dioxaphosphepin (formula 1), comprising the following steps: a) addition of 2,2′-dihydroxybiphenyl, which is suspended in an inert solvant. into a reactor to an excess of phosphorous trichloride under inert gas and stirring; b) discharge and neutralization of the resulting gases from the reaction mixture; c) separation of the excess phosphorous trichloride and the solvant; d) obtention of 6-chlorodibenzo[d,f][1,3,2]-dioxaphosphepin.

The invention relates to a process for preparing 6chlorodibenzo[d,f][1,3,2]dioxaphosphepin, compound 1.

Compound 1 is a building block which plays an important role in, interalia, the synthesis of ligands.

An example of such a ligand is the compound 2,6,6′-[(3,3′-di-tert-butyl-5,5′-dimethoxy-1,1′-biphenyl-2,2′-diyl)bis(oxy)]bis(dibenzo[d,f][1,3,2]dioxaphosphepin),referred to as biphephos, which has found widespread use in transitionmetal-catalyzed reactions.

The compound 2 is used, for example, in the transition metal-catalyzedhydroaminomethylation (E. Petricci, A. Mann, J. Salvadori, M. Taddei,Tetrahedron Letters 2007, 48, 8501-8504), hydrocyanation (U.S. Pat. No.5,449,807), hydroformylation (U.S. Pat. No. 4,769,498, CN1986055),isomerization (U.S. Pat. No. 5,440,067) and cyclohydrocarbonylation(U.S. Pat. No. 5,962,744) of olefins.

Compound 2 is usually prepared from commercially available startingmaterials in three synthesis steps: to produce the backbone,3-tert-butyl-4-hydroxyanisole is oxidized to the biaryl compound3,3′-tert-butyl-2,2′-dihydroxy-5,5′-dimethoxybiphenyl. To produce theside wings, phosphorus trichloride is reacted with2,2′-dihydroxybiphenyl to form compound 1. Finally, the reactionproducts of the two steps mentioned are condensed with one another inthe presence of a base to form biphephos 2.

All processes known hitherto for preparing compound 1(6-chlorodibenzo[d,f][1,3,2]dioxaphosphepin) lead to formation ofundesirable by-products and thus a reduced yield or else require a highoutlay in terms of energy or time.

Thus, in U.S. Pat. No. 4,769,498 phosphorus trichloride is addeddropwise to 2,2′-dihydroxybiphenyl, forming phosphitic by-products whichcan be substantially suppressed only by energy-intensive thermalequilibration for a number of hours (cf. L. Anschutz, W. Marquardt,Chem. Ber. 1956, 89, 1119-1123) or/and a complicated vacuum distillationof the product has to be carried out, requiring either very hightemperatures (ibid and in L. V. Verizhnikov and P. A. Kirpichnkov, Zh.Obshch. Khim., 1967, 37, 1355) or vacuums of 130 Pa and less which aredifficult to realize industrially (EP 0 730 574 and V. N. Tsarev, A. A.Kabro, S. K. Moiseev, V. N. Kalinin, O. G. Bondarev, V. A. Davankov, K.N. Gavrilov, Russ. Chem. Bull., Int. Ed. Vol. 53, 2004, 814-818).

In CN1986055, on the other hand, an excess of phosphorus trichloride isplaced in a reaction vessel and 2,2′-dihydroxybiphenyl is added thereto.However, further details regarding the manner of the addition, and alsothe reaction conditions for a compound which is as highly reactivetoward phosphorus trichloride as 2,2′-dihydroxybiphenyl are notprovided. Compound 1 is separated from the reaction mixture and purifiedfurther by means of vacuum distillation, but once again further detailssuch as pressure and temperature range are absent. The yield of 1 isonly 71%. Closer characterization of 1 is not disclosed.

The analogous process disclosed in FR 2873696 requires energy-intensivecooling of the reaction mixture to 0° C. in order to obtain sufficientselectivity and the addition of an amine to scavenge the hydrogenchloride gas formed, with the consequence that an amine hydrochloridewhich has to be filtered off is formed. However, since the entirereaction mixture is highly corrosive, it requires an expensivefiltration apparatus (because it has to be corrosion resistant), forexample a filtration apparatus made of DIN 2.4610 alloys. In addition,the amine hydrochloride waste formed has to be disposed of or recycled,which is expensive.

Furthermore, the authors have established that in the process intetrahydrofuran described by A. van Rooy, P. C. J. Kamer, P. W. N. M.van Leeuwen, K. Goubitz, J. Fraanje, N. Veldman and A. L. Spek inOrganometallics 1996, 15, 835-847, the addition of base described thereis not permissible since otherwise up to 10% of by-products formed byacid cleavage of tetrahydrofuran could be formed. However, the necessaryaddition of an amine once again requires the expensive filtration and/ora vacuum distillation.

Furthermore, apart from the aspects product yield and purity, it iscritical that the addition of the 2,2′-dihydroxybiphenyl is carried outin such a way that the removal of heat from this condensation reactionis carried out in a controlled way in order for the process of theinvention to be carried out safely, especially with a view toimplementation as an industrial process.

In Zh. Obshch. Khim., 1967, 37, 1355, L. V. Verizhnikov and P. A.Kirpichnkov report a process variant in which the starting materialsphosphorus trichloride and 2,2′-dihydroxybiphenyl are mixed at roomtemperature, heated to boiling and the product is subsequently separatedoff by high-vacuum distillation. Since two highly reactive compounds aremixed directly there, the criterion of controlled heat removal can nolonger be guaranteed in the case of large batches. The heat of reactionis −54 kJ/mol and the reaction is therefore strongly exothermic.However, controlled heat removal is absolutely necessary on anindustrial scale for safety reasons. Otherwise, the entire quantity ofheat could be liberated suddenly on direct mixing of two highly reactivecompounds. This quantity of heat can still be removed without danger inthe case of small laboratory batches, but in the case of reactions on anindustrial scale there is a considerable hazard potential.

It is therefore an object of the invention to develop a process whichprovides compound 1 from 2,2′-dihydroxybiphenyl and phosphorustrichloride in high yield and purity without making recourse toenergy-intensive equilibration or cooling operations and makes dowithout product distillation, addition of base or use oftetrahydrofuran. In the ideal case, the process can also be managedsafely on an industrial scale.

It has been found that this object can be achieved by a process forpreparing 6-chlorodibenzo[d,f][1,3,2]dioxaphosphepin, which comprisesthe following steps:

-   a) addition of 2,2′-dihydroxybiphenyl suspended in an inert solvent    to an excess of phosphorus trichloride under inert gas in a reactor    and stirring;-   b) discharge and neutralization of the resulting gases from the    reaction mixture;-   c) removal of the excess phosphorus trichloride and also of the    solvent, preferably after the end of the reaction;-   d) isolation of 6-chlorodibenzo[d,f][1,3,2]dioxaphosphepin.

The addition of the 2,2′-dihydroxybiphenyl as a suspension in an inertsolvent to an excess of phosphorus trichloride is critical to theprocess of the invention. In particular, a 2- to 25-fold, preferably 10-to 15-fold, excess of phosphorus trichloride, based on molar ratios, ispresent here. The addition of 2,2′-dihydroxybiphenyl is particularlypreferably carried out in a pressure range from 0.07 to 0.12 MPa. Forthe purposes of the present invention, inert solvents are in principleall solvents which are stable and unreactive under the conditionsmentioned. The inert solvent is preferably an aromatic hydrocarbon orhydrocarbon mixture, for example xylenes or toluene, in particular,toluene. In the case of aromatic hydrocarbon mixtures, these preferablycontain predominantly toluene, in particular more than 50% by weight oftoluene. Additions of suspensions are usually difficult to carry outindustrially since settling solid particles quickly lead to blockage offeed lines. This suspension is preferably set to the following valueranges of the following parameters, where:

-   -   the solids content of the suspension varies within a range from        ≧10 to 60% by mass and    -   at least 90% of the particles of the suspended        2,2′-dihydroxybiphenyl have a size of ≧1 to ≦1000 microns.

The control and monitoring of these parameters is ensured, for example,by means of commercially available laser light scattering, which isadequately known to those skilled in the art. When the solids contentapproaches, for example, the lower limit, the suspension can be mixedagain by renewed stirring and the solids content can thus be increasedagain.

After the reaction is complete, excess phosphorus trichloride and theinert solvent or solvents, preferably containing predominantly toluene,are removed. This removal is preferably carried out by means ofdistillation, preferably under sub-atmospheric pressure which isparticularly preferably a fractional distillation. Recovered phosophorustrichloride and the solvent are reused in the synthesis process.Compound 1 remains in approximately quantitative yield and in highpurity.

This embodiment of the invention surprisingly shows that only minimalamounts of by-products are formed at ambient temperature and withoutaddition of base and that the sedimentation rate of2,2′-dihydroxybiphenyl in toluene is so low that no troublesome blockageprocesses or lump formation processes are observed even in the case ofonly gentle stirring in the feed reservoir.

Even without further details, it is assumed that a person skilled in theart can utilize the above description in its widest scope. The preferredembodiments and examples are therefore to be interpreted merely asdescriptive disclosures which do not limit the invention in any way. Thepresent invention is illustrated below with the aid of examples.Alternative embodiments of the present invention can be obtained in ananalogous way.

EXAMPLE

177.65 g (960 mmol) of pulverulent 2,2′-dihydroxybiphenyl in which atleast 9015 of the crystals have a particle size in the range from 1 to1000 microns were suspended in 710.61 g of toluene with stirring in a1000 ml starting material reservoir which had been made inert by meansof nitrogen. Adherence to this particle size distribution isadvantageous for the stability of the suspension. The solids content ofthe suspension of up to 60% was monitored by means of laser lightscattering. When this value approached the lower limit of 10% by mass,the upper limit was restored by resuming stirring. 1574 g (11.46 mol) ofphosphorus trichloride were placed in a 6000 ml reactor which had beenmade inert by means of nitrogen. To control the evolution of heat, the6000 ml reactor was thermostated to 20° C. and stirred. The reactor wasconnected via a waste air scrubber filled with sodium hydroxide solutionto a membrane pump. A working pressure of from 0.07 to 0.09 MPa was setto ensure that gases formed were safely discharged via the waste airscrubber. The starting material reservoir was installed above thereactor and at its lowest point was connected via a glass tube to thelid of the reactor. At the outlet of the starting material reservoir,the flow of suspension was regulated by means of a ball cock. Thecontent of the starting material reservoir was introduced into thereactor over a period of 2.5 hours. The cock had to be opened slightlyand closed slightly at times. No blockage or lump formation occurred.After the addition was complete, the mixture was stirred at 20° C. for15 minutes, after which a clear, slightly yellowish solution was presentin the reactor. The reactor was subsequently evacuated to 0.02 MPa andheated to 50° C. Excess phosphorus trichloride and toluene-containingsolvent were distilled off into receivers made inert by means ofnitrogen. The reaction temperature was increased stepwise to 91° C.After 2.25 hours, the distillation was concluded. A virtually colorless,highly viscous liquid remained.

Yield: >99% of theory. Purity: 98%; determined by GC/MS and ³¹P-NMRmeasurement (500 MHz high-field measurement using 85% orthophosphoricacid as external standard, 1 dissolved in d8-toluene) at a shift ofδ=185.21 ppm.

The invention claimed is:
 1. A process for preparing6-chlorodibenzo[d,f]-[1,3,2]dioxaphosphepin, which comprises: a) addinga suspension of 2,2′-dihydroxybiphenyl in an inert solvent to an excessof phosphorus trichloride under inert gas in a reactor and stirring, toobtain a reaction mixture and resulting gas; b) discharging andneutralizing the at least one resulting gas from the reaction mixture;c) removing excess phosphorus trichloride and also the solvent; and d)isolating 6-chlorodibenzo[d,f][1,3,2]dioxaphosphepin.
 2. The process ofclaim 1, wherein the suspension comprising 2,2′-dihydroxybiphenyl has asolids content in a range from 10 to 60% by mass.
 3. The process ofclaim 1, wherein at least 90% of particles of the 2,2′-dihydroxybiphenylin the suspension have a particle size of from 1 to 1000 microns.
 4. Theprocess of claim 1, wherein the inert solvent comprises an aromatichydrocarbon or hydrocarbon mixture.
 5. The process of claim 4, whereinthe aromatic hydrocarbon mixture is present and comprises predominantlytoluene.
 6. The process of claim 1, wherein the removing of excessphosphorus trichloride and the solvent, comprising an aromatichydrocarbon mixture, is carried out by distillation under subatmosphericpressure.
 7. The process of claim 1, further comprising: reusingphosphorus trichloride and aromatic hydrocarbon removed by fractionaldistillation in the process.
 8. The process of claim 2, wherein at least90% of particles of the 2,2′-dihydroxybiphenyl in the suspension have aparticle size of from 1 to 1000 microns.
 9. The process of claim 1,wherein the inert solvent comprises an aromatic hydrocarbon.
 10. Theprocess of claim 1, wherein the inert solvent comprises a hydrocarbonmixture.
 11. The process of claim 1, wherein the inert solvent comprisesmore than 50% toluene.
 12. The process of claim 1, wherein the inertsolvent is toluene.
 13. The process of claim 1, wherein the inertsolvent comprises xylenes.
 14. The process of claim 1, wherein the inertsolvent is xylenes.
 15. The process of claim 1, wherein the phosphorustrichloride is present in a 2- to 25-fold excess in the adding a), basedon molar ratios.
 16. The process of claim 1, wherein the phosphorustrichloride is present in a 10- to 15-fold excess in the adding a),based on molar ratios.
 17. The process of claim 1, wherein the isolatingd) does not comprise distilling6-chlorodibenzo[d,f][1,3,2]dioxaphosphepin.
 18. The process of claim 1,wherein equilibration or cooling operation are not employed.
 19. Theprocess of claim 1, wherein tetrahydrofuran is not employed as solvent.